Wall construction



@QL Jg 1932- M. L. WEBSTER QQQSE WALL CONSTRUCTION Film1 Eafch 19, 1930 Patented Oct. 4, 1932 o f l,88,55l

MAUR-Y L. WEBSTER, OF SANTA IVIONICA, GALFORNIA WALL CONSTRUCTION Application filed March 19, i930.

My invention relates to a wall construction suitable for a furnace or other structure in which one side of the wall is heated to a high temperature.

A considerable difiiculty has been experienced in connection with walls of furnaces made of bricks or blocks which are usually made with the fire or refractory bricks or blocks forming the inside wall and common bricks forming the outside portion of Vthe wall. It has been more or less common practice to set up the refractory block part of the wall without adequate expansion joints for the blocks, frequently with the blocks in contact, which does not allow for the expansion of these refractory blocks when subjected to the high temperature of the furnace. lf the bricks are imbedded in mortar and have mortar vertical joints this mortar disintegrates at the high temperatures; such disintegration applies to fire clay mortar beds as well as the ordinary lime and cement mortar beds. The disintegrated joint material then falls off the joints between the refractory blocks or sifts downwardly forcibly pressing the blocks in wardly. Adjacent the side subjected to the highest temperature the blocks or bricks expand to greater extent than the portion of the blocks or bricks which is imbedded in the wall: this causing the blocks or bricks to have a somewhat wedge shape and in a large wall this bows inwardly having a convex interior curve, considered horizontally and vertically, forming in effect an inward bulging of the wall from end to end and from top to bottom. This has been found to progress until the wall either falls in or requires to be taken down and rebuilt.

An object therefore of my invention is to construct a block or brick wall for a furnace having a refractory block lining with a common block or brick construction for the Outside portion of the wall and to bed the refractory blocks in such a manner that the expansion is taken care of between the joints of the refractory blocks and such blocks, when fully expanded Ado not press against each other with su'fiicient force to cause a bulging inwardly of the wall. A feature therefore of my invention in this connection is in bedding Serial No. 437,041.

the blocks in layers using a fire clay mortar, this being mixed to the proper consistency with water and leaving the vertical joints between the blocks without any mortar. The common blocks or bricks are bonded into the 55 refractory blocks or bricks using a mortar joint and bedding of the ordinary type. Therefore by this construction when the wall is subjected to heat the water of crystallization' is driven out of the fire clay mortar and causes this to contract usually about 50% and in fact to disintegrate to a certa-in extent adjacent the inside of the wall which is subjected to the greatest temperature.

Thisleaves the joints between the refractory bricks or blocks on the inside practically open and gives room for expansion of the blocks or bricks considered both horizontally and vertically. rlhe size of the joints is calculated so that in any Vexpansion which may occur there will not be sufficient pressure from one block to the other to cause the inward bulging of the wall.

Another feature of my invention comprises Y a construction by which the wall is bound to 7" an exterior metal construction. Such binding is preferably by means of an anchor bar which engages the exterior metal construction and is bound into the brick or block work, engaging the inside of the common bricks or blocks. In this construction I preferably use angle bars which have one iiange imbedded in a horizontal joint or bed between adjacent beds or layers of bricks or blocks and with the other iiange extending downwardly of the outside face of the wall. The angle straps are preferably in the form of a Z shape and engage the outside of the angle bars and the interior of the wall. v

My invention is illustrated in connection with the accompanying drawing in which,

Fig. l is a partial elevation showing the inside of the wall,

Fig. 2 is a partial elevation showing the outside of the wall,

Fig. 3 is a vertical section on the line 3 3 of Fig. l in the direction of the arrows,

Fig. l is a partial horizontal section on the line 4 4 of Fig'. 3 in the. direction of the arrows,

Fig. 5 is a partial horizontal section on the line 5 5 ofFig. 3 in the direction of the arrows,

Fig. 6 is a perspective view of one of the anchor straps,

Figs. 7 and 8 illustrate the type of hatching and surfacing used to indicate the refractory and the common blocks or bricks.

In the drawing the refractory blocks or bricks are designated by the numeral 11, these being on the inside of the wall and the common blocks or bricks 12 forming the outside portion of the wall. tration the refractory blocks are imbedded in mortar 13 preferably made of fire clay `mixed with water to the proper consistency to hold one layer of bricksl on another with the proper spacing of the bed. .Vhen bricks are used the common bricks are usually slightly thinner than the refractory bricks so 'that the joint 14, between the common bricks, is thicker than for the refractory bricks. This joint is usually made of lime mortar and to hasten the setting a certain amount of cement is added.

In the illustration, the inside wall is layed up with rows of headers 15 and alternate rows of stretchers 16. The outside Wallis illustrated also as being layed with rows of headers 17 and rows of stretchers 18. The .particular wall illustrated is two-and-onehalf bricks thick, considering the length of the bricks in the measurement, but a satis-v .factory wall for certain purposes can be readily made two bricks thick and the thickness can be increased where necessary.

In laying up the refractory bricks or blocks these are butted together in the interior of the wall, as indicated at 19, and the common blocks or bricks will also butt against the refractory blocks or bricks, as indicated at 20. The common blocks have vertical mortar interior joints 21 and have vertical joints 22 being imbedded or filled with mortar. However the vertical joints 23 of the refractory blocks or bricks are open spaces without any fire clay or other mortar. In laying up a wall of this character it is preferable to use guide-spacers to space the blocks the proper distance apart until the bricklayer becomes skilled in this type o-f vwall construction. It will be noted that this type of bonding gives a diagonal supporting bond considering from the exterior to the interior of the wall. rlherefore after the fire clay beds 13 vhave contracted, and to a cere tain extent disintegrated, the blocks facing the interior of the furnace are still properly supported.

In addition to this construction l use metal bars to prevent inward bulging of the wall, such bars are designated generally by the numeral 24; and consist of angles having a flange 25 extending into the mortar bed between layers of brick and having an outside flange In thev illus- 26 extending downwardly over the face of the layer of bricks or blocks. These bars are quite long and usually reach from one corner to the other corner of the furnace and therefore may be considered as supported at the corners. However, the brick wall will be free to bulge Ainwardly as the flange 25 will slip in its mortar bed. ln order to anchor the wall to these bars l utilize anchor straps 27: These are illustrated as having a web 23 with flanges 29 forming` a 2 shaped bar. One of the flanges is caught over the outside flange o-f the angle bar, the web lits in the mortar space between adjacent layers of common brick or block and the other flange fits behind the inner end of one of the common blocks or bricks and in a wall of the thickness illustrated preferably behind one of the header blocks o-r bricks, such hea-der being cut a little short to give space to accommodate the thickness of the flange 29. rlhe joint space above the flange, indicated at 30, may be filled with mortar. f

lith a wall of this construction the interior is usually subjected toa very high temperature which causes a complete drying of the fire clay bed for the bricks adjacent the inner wall, driving off the water of crystallization which allows a contraction of this fire clay of frequently more than 50%. The fire clay also in a sense disintegrates having no bonding action, and acertain amount, due to the gas and air blasts in the furnace, will fall out of the inside oints. Therefore a certain amount of the re clay in the joints 13 adjacent the inside wall is reduced in thickness and strength or altogether disappears so that for practical purposes the horizontal layers of the refractory bricks or blocks on the inside have an open joint. The vertical joints 23 have been left open so that when the interior bricks or blocks expand such expansion can take place until these open joints are closed without the adjacent blocks or bricks contacting and should they come in contact the expansion has usually been sufficiently taken care of so that there is insufficient force to bulge the wall inwardly. On contraction of the blocks or bricks they return to their original condition. Manifestly some of the heat is conducted to the interior of the wall but the refractory blocks or bricks have sufficient room for expansion without damage to the wall.

Should there be a. tendency for the wall to bulge inwardly, due to the expansion forces, the anchor straps 27 exert a pull on the angle bars 24, which, as above mentioned, are supported at opposite ends and are of the proper strength to resist the inward bulge of the wall. The bonding of the bricks is suihcient so that considerable stress may be transferred to the anchor straps. The bars 2st are free to expand longitudinally and in transverse directions without injuring the wall whatever. The anchor straps 27 can also expand without any injury to the wall but the metal parts are not subjected to high temperatures and in fact function somewhat as head radiating portions in the wall. In building the wall the bars 24 are placed distances apart found to be suitable by practice. The anchor straps are also positioned as has been found necessary.

In building walls of the above type it is desirable to have the common blocks of lesser thickness than the refractory blocks and when the common blocks are of less thickness than the refractory blocks the bedding joints must be made sufficient thickness for the common blocks so that they bed in aligning layers with the refractory blocks. If for any reason the refractory and the common blocks or bricks are of materially different thicknesses the common blocks should be bedded so that at any layer of the refractory blocks there will be a bedding joint for both the refractory and common blocks. It is obvious that if desired I may build the wall so that the horizontal bedding oint for the refractory blocks or bricks on the inside is left without a supporting mortar and the vertical joints may also bc left without a supporting mortar, or if desired these vertical joints may have mortar placed therein such as fire clay which under heat will dry out and contract and to a certain extend disintegrate. Any type of joint for the refractory blocks or bricks is suitable which will allow for the free expansion of the heated end and the remaining portion of these blocks or bricks sothat undue pressure is not exerted between adjacent blocks or bricks and thus the inward bulging of the wall is prevented.

I claim as my invention:

l. A furnace wall having refractory blocks on the inside, the common blocks on the outside and common blocks being bedded in a mortar bed and bonding with the refractory blocks, mortar bedding for the refractory blocks having a characteristic of allowing considerable shrinkage when subjected to the temperatures of the furnace and shrinking away from. the joint thereby leaving open joints between the refractory blocks on the inside of the furnace wall, which joints accommodate the expansion of the refractory blocks due to the heat of the furnace.

2. A furnace wall formed of refractory blocks on the inside and common blocks on the outside, the common blocks being bedded in mortar, the refractory blocks having niortared beds formed of lire clay, the refractory and common blocks bonding together such iire clay having the characteristic of considerable shrinkage adjacent the inside surface of the wall when subjected to the furnace temperatures, thereby leaving `joints with sufficient space for the expansion of therefractory blocks adjacent the inside surface of the furnace without said blocks exerting excessive pressure one against the other.

3. A furnace wall having refractory blocks on the yinside and common blocks on the outside, the common blocks being bedded in mortar, the refractory blocks having bedding -of material adapted to shrink when subjected to high temperatures, said bedding forming joints between some of the refractory bricks on the inside surface of the wall other joints on the inside surface being open, the refractory and common blocks being bonded together the said joints affording a space for the expansion of the refractory blocks when subjected to the furnace temperatures without said blocks exerting suiicient pressure one against the other to cause an inward bulging of the wall.

4. A furnace wall having refractory blocks or bricks Von the inside and common blocks or bricks on the outside, the outside blocks being bedded on mortar beds and having mortar vertial joints, the refractory blocks being bedded on horizontal beds formed of fire clay, the refractory and common blocks bonding together there being vertical open joints between the refractory blocks on the inside of the wall, the fire clay having the characteristic of considerable shrinkage when subjected to high furnace temperatures whereby the horizontal and vertical joints afford a space for the expansion of the inner portion of the refractory blocks without such blocks exerting suiiicient pressure one against the other to develop a wedge shape and bulge the wall inwardly.

5. A furnace wall having refractory blocks on the inside and common blocks on the outside, the refractory blocks being bedded in layers and the common blocks being bedded with mortar in layers whereby the refractory and common blocks have a horizontal bedding in the same plane the said refractory and common blocks being bonded together the refractory blocks being built into the wall with joints on the inside surface such joints .forming a space for the expansion of the refractory blocks when subjected to the heat of the furnace thereby preventing sufficient pressure of the refractory blocks one on the other to cause inward bulging of the wall.

6. A furnace wall having refractory blocks on the inside and common blocks on the outside; common blocks being bedded in horizontal layers with a mortar bedding, the refractory blocks having layers with a horizontal bedding formed of fire clay or the like, said horizontal bedding being in the same horizontal plane for the refractory and the common blocks, the refractory blocks having open vertical joints on the inside the fire clay adjacent the inside of the furnace being adapted to contract when subjected to furnace temperatures, and horizontal joints with sufficient space whereby, with the vertical joints, provision is made for expansion of the refractory blocks.

f 7 .i A furnace wall having refractory 'blocks on the inside and connnon blocks on the outside, common blocks being bedded lin horizontal layers with a mortar bedding, the refractory blocks having layers with a horizontal bedding formed of fire clay or the like, said horizontal bedding being in the saine horizontal plane for the refractory and the common blocks, the refractory blocks having open vertical oints on the inside, the fire clay adjacent the inside of the furnace being adapted to contract when subjected to furnace temperatures, and horizontal joints with sufficient space whereby, with the vertical joints, provision is made for expansion of the refractory blocks there being metal supporting structures on the outside of the furnace and anchors extending from said metal structures and bonding in the interior of the wall.

8. A furnace wall forined of blocks built up on mortar beds, angle bars on the outside ofthe wall each having afiange fitting in a mortar bed with a flange on the outside of the wall and metal anchors engaging the outside flange and having a bond in the interior of the wall, the anchors being formed of Z shaped straps having a ange engaging the flange of the bars and an interior flange litting in a joint between adjacent blocks in the interior of the wall.

9. A furnace wall having refractory blocks on the inside and common blocks on the outside, the common blocks being bedded in inorwith an outside flange engaging the flange on the outside of the angle bar and having an interior flange extending in a joint between blocks in the interior of the wall.

10. A furnace wall having refractory blocks on the inside and common blocks on the outside, the common blocks being bedded in mort-ar, said blocks being bonded together, an angle bar extending along the outside surface and-having a flange fitted in one of the beds between the common blocks and having another fiange on'the outside surface, and metal anchors formed of shapedstraps with an outside flange engaging the flange Yon the outside of the angle bar and having an interior flange extending in a joint between blocks in the interior of the wall, the refractory blocks having a bedding of material adapted to shrink when subjected to high temperatures and leave substantially open joints between the refractory blocks on the inside of the wall whereby the refractory blocks may expand7 said joints accommodating the expansion of the refractory blocks.

11. A furnace wall having refractory blocks on the inside and common blocks on flange on the outside face of the connnon blocks, and anchor straps having an outer flange engaging the outer flange of the bar with a web oetween the common blocks and with an inner flange binding in a vertical joint of the common blocks of the wall, the

joints in the refractory blocks accommodating the expansion of such blocks.

12. A- furnace wall having refractory blocks on the inside and common blocks on the outside, the common blocks being bedded in mortar beds, means to support the refrac- Y tory blocks with the contiguous blocks spaced apart, forming open joints on the inside of the wall, said open joints adording a space for the expansion of the inside portion of the refractory blocks due to the temperature of the inside of the furnace.

13. A furnace wall having refractory blocks on the inside and common blocks on the outside, the common blocks being bedded in a mortar bed and bonding with the refrac tory blocks, a bedding for the refractory blocks supporting and spacing the surfaces of contiguous blocks apart, the bedding for the refractory blocks having the characteristic of allowing for considerable shrinkage L i when subjected to the temperatures of the furnace and thereby forming open joints on the inside of the furnace between the refractory blocks to accommodate the expansion of 4 such vblocks due to the heat of the furnace.

11i. A furnace wall having refractory blocks on the inside and common blocks on the outside, the common blocks being bedded on a mortar bed and bonding with the refractory blocks, the bedding for the refractory blocks spacing adjacent blocks apart in horizontal rows, there being open vertical joints between the refractory blocks, the bedding having the characteristic of allowing considerable shrinkage when subjected to the temperatures of the furnace and thereby leaving the portion of the horizontal oints adjacent the inside surface of the furnace open,

which horizont-al open oints and the vertical open vjoints provide room for expansion of the refractory blocks on the inside of the furnace due to the heat of such furnace.

15. A furnace wall formed of refractory blocks on the inside and common blocks on the outside, the common blocks having a mortar bedding, there being vertical internal joints between the common and the refractory blocks on the inside of the furnace, a metal bar extending along the outside wall, a metal anchor having one end engaging such bar having a central portion embedded in a joint of the common blocks and having an inner end fitting in the internal joint between the common and the refractory blocks.

16. A furnace wall formed of refractory blocks on the inside and common blocks on the outside, said common blocks having horizontal joints with a mortar bedding, a bar extending along the outside of the furnace, a metal anchor having an outside portion engagino' said bar, a centrai portion bedded in the horizontal joint of the common blocks, the said common blocks and refractory blocks meeting ith a vertical joint and the inner end of the anchor having an end extending ito one of said joints.

17 furnace wall formed of refractory blocks on the inside and common blocks on the outside, the common blocls being bedded in mortar and having horizontal joints, there being vertical internal joints at the abutting` ends of the refractory and common blocks, an angle bar on the outside of the furnace having one flange Xtending in the horizontal mortar joint of the common blocks and the other end ei-:tending on the outside face of the wall, a Z shaped metal anchor having a central portion in the horizontal metal of the common bloc rs and one end bent over the angle and the other end extending into th-e joint between the abutting ends of the common and refractory block.

18. A furnace wall as claimed in claim 17, the refractory blocks having horizontal layers with a bedding, said bedding supporting the adjacent blocks spaced apart, the said bedding having the characteristic of shrinking when subjected to the heat of the furnace and forming open horizontal and vertical joints of the refractory blocks on the inside of the wall, the open joints providing for expansion of the refractory blocks due to the heat of the furnace.

i9. A furnace wall formed of blocks with refractory blocks on the inside, said blocks having a horizontal mortar bedding Vbetween the layers of blocks and vertical joints, a metal bar ext-ending along the outside of the wall, a metal anchor having one end engaging such bar and having an inner end portion embedded in a vertical joint, the mortar bedding for the refractory blocks on the inside of the wall having the characteristic of allowing considerable shrinkage when subject to the temperature of the furnace and shrinking away from the joint, thereby leaving open joints between the refractory blocks on the inside ofthe furnace wall, which joints accommodate the expansion of the refractory bloclzsdue to the heat of the furnace.

20. A furnace wall formed of blocks, the blocks on the inside of the wall being refractory and having a horizontal mortar bedding between the layers of blocks and vertical joints between adjacent blocks, a metal angle on the outside of the furnace extending along such outside wall, means to anchor said bar in the bedding of the blocks, the bedding between adjacent layers of refractory blocks spacing such blocks apart, and the mortar bedding having the characteristic of shrinking when subjected to the heat of the furnace and forming open horizontal joints of the refractory blocks on the inside of the wall, the open joints providing for expansion of the refractory blocks due to the heat of the furnace.

2l. A wall formed of blocks, the inside blocks being refractory, a horizontal mortar bedding for the layers of blocks and a mortar for th-e vertical joints between the blocks, a metal bar extending along the outside of the wall and having a iiange extending into the horizontal bedding, and means to anchor the bar and such latter flange in the wall, the mortar bedding supporting the adjacent blocks spaced apart, said bedding having the characteristic of shrinkinga when subjected to the heat of the furnace and forming open horizontal and vertical joints of the refractory blocks on the inside of the wall, the open joints providing for expansion of the refractory blocks due to the heat of the furnace.

22. A furnace wall formed of blocks, the blocks on the inside being refractory, a horizontal mortar bedding for the dierent layers of blocks, the vertical joints of the blocks also having a mortar bedding, a metal angle extending along the outside of the wall having one flange extending in the horizontal bedding adjacent the outside wall, a Z-shaped bar engaging said angle and having one end fitting between adjacent blocks of a layer, said bedding supporting the adjacent blocks spaced apart, the said bedding having the characteristic of shrinking when subjected to the heat of the furnace and forming open horizontal and vertical joints of the refractory blocks on the inside of the wall, the open joints providing for expansion of the refractory blocks due to the heat of the furnace.

ln testimony whereof I have signed my naine to this specification.

MAURY L. WEBSTER.

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